Process of Manufacturing Artificial Turf

ABSTRACT

The invention described herein pertains to carpeting of artificial turf used on sports fields, as decorative touches in gardens and areas with greenery as well as for other applications. It features a weaving process differentiated from those normally implemented by the current artificial turf industry, leading to multiple benefits that impact not only the fabricator but also the final user.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention pertains to carpeting of artificial turf featuringimprovements in the weaving method. The product can be used coveringsports fields, acting as decorative accents in gardens, greenery and forother applications. It is based on a weaving method different from thatfor the products normally assembled by today's artificial turf industry,leading to several improvements as much during fabrication as it doesfor the end user.

2. Description of Related Art

Nowadays different methods are implemented in the manufacturing ofartificial turf. To the extent that it has been possible, the industryhas labored intensely perfecting the appearance and performance of itsoutput resulting in more benefits for the consumer. Continuously,materials used for its fabrication as well as the structure and designare being improved. Most artificial turf surfaces display similarcharacteristics such as: color, synthetic materials, similar weaving andmanufacturing methods and installation, among others.

The materials and processes applied to this type of product includechemical compounds that may enhance its resiliency, occasionallygenerating unusual properties. However, they still do not totally appearlike real turf. They create a surface with a texture and layout much tooregular, very different from the look of natural grass. Therefore, thepurpose of this report is to analyze our covering of artificial turfthat features improvements in the weaving method, and will beillustrated below with graphics along with its advantages which willmake evident the improvements that, doubtlessly surpass today'stechnology with respect to artificial turf carpeting.

Nowadays, a tufting machine uses an array of needles, a thread-feedingmechanism called a “creel” and a line for the finish. Carpets areconstructed using three basic elements: a) cloth fabricated withintertwined flat polypropylene strings; b) threads that resemble thestems and leaves of grass made of polyethylene, polypropylene or nylon,and c) a coating applied to the lower face that may be made of latex orpolyurethane. These days, the steps of the weaving process follow thisapproach: the tufting machine fastens the threads upon the cloth whichcomes in rolls and the threads are kept on bobbins or spools.

The cloth is placed on a special accessory allowing the machine to pullit as it is weaving. Afterwards, the spools of thread are fitted to acreel according to the number of needles used by the machine. Thethreads are guided by individual polyethylene tubes from the bobbin tothe tufting machine. The thread enters the machine via a feeding systemwith rollers until it reaches the needles. The thread is strung throughthe eye of the needle, ready for insertion through the cloth. The actionof the tufting machine introduces the threads through the cloth and cutsthem at a set length.

Once the carpet exits the machine, the former is inspected and the weaveis repaired as necessary. Subsequently the product is rolled up, madeready for the final coating. Following the process described above, andwhen the carpet has exited the weaving operation, the product must becoated with latex or polyurethane in order to bond the threads therebyproviding strength, protection and consistency. The final coatingconsists of applying a material composed of latex or polyurethane on thelower surface of the carpet. The carpet is guided to a moving belt andenters an area where the material (latex or polyurethane) is applied asa liquid. Afterwards it reaches the oven that cures the coating. Thecarpet continues along a moving belt and when it exits the oven, it isperforated for the purpose of draining water that falls upon it when inuse. Then, the carpet keeps moving along the belt until the coatingcools completely. Finally, it arrives at the inspection and packagingstation where the quality is checked, the carpet is rolled up and it iswrapped inside a polyethylene plastic film.

SUMMARY OF THE INVENTION

The invention described herein pertains to carpeting of artificial turfused on sports fields, as decorative touches in gardens and areas withgreenery as well as for other applications. It features a weavingprocess differentiated from those normally implemented by the currentartificial turf industry, leading to multiple benefits that impact notonly the fabricator but also the final user.

BRIEF DESCRIPTION OF THE DRAWINGS

The objective of the invention presented here will be better understoodwith the following descriptions of examples from real operations. Thedescriptions relate to the graphics attached herein, including:

FIG. 1 that shows an exploded view of the artificial turf carpeting,subject of this report.

FIG. 2 that shows the horizontal view of the improved weave of theartificial turf carpeting, subject of this report.

FIG. 3 that shows the vertical view of the improved weave of theartificial turf carpeting, subject of this report.

FIG. 4 that shows the view from above demonstrating the concentration ofthe aggregates of threads produced by this new weaving process.

FIG. 5 is a perspective view of the dispensing container of FIG. 1,showing an outermost plastic bag being dispensed from the roll.

FIG. 6 is a perspective view of the dispensing container of FIG. 1,showing an arresting tab of the dispensing container catching anadjacent inner plastic bag through its handle hole.

FIG. 7 is a perspective view of the dispensing container of FIG. 1,showing the outermost plastic bag being removed from a bag roll whilethe adjacent inner plastic bag is caught on the arresting tab.

FIG. 8 is a top view of a portion of a roll of plastic bags according toone embodiment of the invention, showing two adjacent bags connectedbottom-to-top by a separable perforation.

DETAILED DESCRIPTION OF THE INVENTION

As a consequence of the improved process of weaving (3) the artificialturf carpeting, subject of this report, a wide range of benefits areachieved given that this new weaving process (3) reduces the amount ofthread (1) while presenting the appearance of a heavier turf. Inaddition, the pattern of stitches applied to the lower surface of thecarpet (4), where the coating of latex or polyurethane is spread,presents a larger surface for contact with the finishing material due tothe great majority of the stitches being arrayed diagonally. Thereforethe adhesion to the threads is strengthened (1) compared to the bondobtained from a rectilinear or standard weave. Given the greaterconcentration of threads (1) in certain areas coupled with adistribution simulating the pattern of a chessboard (5), the appearanceof a turf closer to reality is achieved since natural turf does not growin furrows, but rather in a dispersed fashion. This new weaving process(3) eliminates the appearance of turf as though it were an “agriculturalfield intentionally seeded” marked by parallel green lines, and producesa more natural looking turf. Once the aggregates are in place, this sameconfiguration allows for a greater retention of those aggregates due tothe position of the threads (1). In addition, an excessive scattering ofthe aggregate materials is avoided when performing sweeping tasks. In animportant way, this property helps to avoid the migration of theaggregates toward the zones of reduced activities in the field of playand the depletion of those materials at the areas bearing more traffic.This improvement in the weaving process (3) is favored for the surfaceof a sports facility by maintaining greater consistency and therebyenhancing performance of the sport. The intervals separating tufts of“grass”, indicated in FIG. 4, result in greater resiliency due to thisimprovement in the weaving process (3) associated with a suitablecombination of threads (1). With this configuration of turf where ahomogeneous dispersal of the thread lines (1) is built in, the playerscan depend on a uniform distribution of the turf and of the aggregates,and therefore better support yielding more natural running, jumping,stopping and turning. This design considerably reduces reflected lightwhich helps to moderate vision fatigue for both players and theaudience.

The fabrication of artificial turf carpeting presented in this report iscarried out primarily by means of altering the configuration of the bankor array of needles compared to the standard in-line disposition of thatformation, whereby one needle is installed along the same line as thefollowing one, equidistant one from the other, whatever may be theseparation between the needles. In this instance, the distanceseparating the needles in the standard disposition of needles measures½″. This results in a distance between needles on one side and the otherof ½″. By altering the configuration of the bank of needles in order toimprove the weaving technique, 2 needles are placed ¼″ apart, resultingin a gap of ¾″ and 2 other needles are installed ¼″ apart, and so onrepeating the same pattern all along the entire length of the bank orarray of needles. The tufting machine includes a special accessory thatdisplaces the bank of needles horizontally causing the needles topenetrate the cloth in a normal or standard manner. At the next stitch,the bank of needles moves horizontally rightward for ½″, resulting in adiagonal stitch. At the following stitch, the bank of needles keeps itsplace resulting in a straight stitch. With the next movement, the bankof needles moves horizontally leftward to a distance of ½″ to exactlythe same starting point producing a diagonal stitch in the otherdirection from the previous diagonal one. Completing the cycle, the bankmaintains its place forming another stitch in a straight line. Thissuccessive motion of the cycle develops into a pattern resemblingsomething like “SS SS SS . . . ” material.

What is claimed is:
 1. Artificial turf featuring improvements in theweaving process executed primarily by way of altering the configurationof the needles arrayed along a bank of needles compared to the standardconfiguration in a straight line on that bank, whereby one needle isinstalled in line with the next one equidistant one from the other,regardless of the separation between the needles. In this instance, theseparation of the standard configuration in the bank of needles measures½″, meaning a separation between needles on one side and the other thatmeasures ½″. In order to implement the improvement of the weave, thealteration of the configuration on the bank of needles is achieved byseparating 2 needles by a distance of ¼″, leaving a gap measuring ¾″ andby installing another 2 needles ¼″ apart. The pattern is repeated alongthe entire length of the bank of needles. The tufting machine is fittedwith a special accessory that causes the bank of needles to movehorizontally in such a way that the needles penetrate the cloth in anormal manner. With the next stitch, the bank of needles is displacedhorizontally rightward for a distance of ½″ producing a diagonal stitch.With the following stitch, the bank of needles remains in placeresulting in a straight woven stitch. For the next movement, the bank ofneedles is repositioned horizontally towards the left at a distance of½″, back to exactly the same starting point forming a diagonal stitch inthe opposite direction from the previous one that was also generateddiagonally. The bank's cycle is completed when the improved array ofneedles is kept in place resulting in yet another stitch in a straightline. The cycle of these successive shifts in position generates apattern akin to “SS SS SS . . . . ”
 2. Artificial turf featuringimprovements in the weaving process.